U.S. patent application number 11/013418 was filed with the patent office on 2005-06-23 for absorbent structure and a method for manufacturing an absorbent structure.
This patent application is currently assigned to SCA Hygiene Products AB. Invention is credited to Doverbo, Anna-Gerd, Fernfors, Ingemar.
Application Number | 20050137551 11/013418 |
Document ID | / |
Family ID | 34680893 |
Filed Date | 2005-06-23 |
United States Patent
Application |
20050137551 |
Kind Code |
A1 |
Doverbo, Anna-Gerd ; et
al. |
June 23, 2005 |
Absorbent structure and a method for manufacturing an absorbent
structure
Abstract
An absorbent body includes a set of first strips and a set of
second strips, wherein the first and second strips are coupled to
each other in order to form an absorbent layer of the body. The
first and second strips are coupled to each other by the first
strips being provided with cuts in which the second strips are
arranged.
Inventors: |
Doverbo, Anna-Gerd;
(Molndal, SE) ; Fernfors, Ingemar; (Molndal,
SE) |
Correspondence
Address: |
BURNS DOANE SWECKER & MATHIS L L P
POST OFFICE BOX 1404
ALEXANDRIA
VA
22313-1404
US
|
Assignee: |
SCA Hygiene Products AB
Goteborg
SE
|
Family ID: |
34680893 |
Appl. No.: |
11/013418 |
Filed: |
December 17, 2004 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60530669 |
Dec 19, 2003 |
|
|
|
Current U.S.
Class: |
604/385.01 |
Current CPC
Class: |
A61F 13/534 20130101;
Y10T 428/24314 20150115; A61F 13/15699 20130101 |
Class at
Publication: |
604/385.01 |
International
Class: |
A61F 013/15; A61F
013/20 |
Claims
1. An absorbent body comprising a set of first strips and a set of
second strips, wherein said first and second strips are coupled to
each other in order to form an absorbent layer of the body, said
first and second strips are coupled to each other by said first
strips being provided with cuts in which said second strips are
arranged.
2. The absorbent body according to claim 1, wherein said cuts have
an extension in a longitudinal direction which is substantially
parallel to the longitudinal direction of said first strips.
3. The absorbent body according to claim 1, wherein said cuts have
an extension in a longitudinal direction which is substantially
perpendicular in relation to the longitudinal direction of said
first strips.
4. The absorbent body according to claim 3, wherein a length of
said cuts, with regard to the extension substantially
perpendicularly in relation to the longitudinal direction of said
first strips, corresponds to approximately half a width of one of
said first strips.
5. The absorbent body according to claim 2, wherein a length of
said cuts, with regard to the extension substantially in parallel
with the longitudinal direction of said first strips, corresponds
to approximately one width of one of said first strips.
6. The absorbent body according to claim 1, wherein said cuts are
substantially L-shaped.
7. The absorbent body according to claim 1, wherein said cuts are
arranged in order to form flaps in said first strips, wherein said
flaps can be turned up or down in relation to said respective first
strip for arranging one of said second strips between the
respective flap and said first strip.
8. The absorbent body according to claim 7, wherein along the
extension of said second strip in the longitudinal direction
thereof, said second strip is arranged between a plurality of flaps
and said first strips.
9. The absorbent body according to claim 8, wherein said flaps are
arranged for locking said second strip in relation to said first
strips in a first direction, being substantially parallel to the
longitudinal direction of said first strips, and in a second,
opposite direction.
10. The absorbent body according to claim 9, wherein the flaps are
arranged alternatingly on said first strips so that, for a given
flap, said second strip is locked in relation to said first strips
in a direction parallel to the longitudinal direction of said first
strips and, by means of the closest adjacent flap along said second
strip, this is locked in the substantially opposite direction.
11. The absorbent body according to claim 7, wherein a portion of
the periphery of the respective flap is formed by a portion of one
of the longitudinal side edges of the respective first strip.
12. The absorbent body according to claim 1, wherein one of the
cuts extends from a position at one of the longitudinal side edges
of a respective first strip and further into the strip.
13. The absorbent body according to claim 1, wherein said second
strips have cuts for receiving said first strips.
14. The absorbent body according to claim 1, wherein said first
strips are arranged substantially in parallel with each other and
said second strips are arranged substantially in parallel with each
other.
15. The absorbent body according to claim 1, wherein said first
strips are arranged substantially in parallel with each other or
said second strips are arranged substantially in parallel with each
other.
16. The absorbent body according to claim 1, wherein said first and
second strips are arranged so that they cross each other.
17. The absorbent body according to claim 15, wherein said first
and second strips are arranged substantially perpendicularly in
relation to each other.
18. The absorbent body according to claim 1, wherein said first
strips are arranged in order to partially overlap each other and
that said second strips are arranged in order to partially overlap
each other.
19. The absorbent body according to claim 1, wherein said first
strips are arranged in order to partially overlap each other or
that said second strips are arranged in order to partially overlap
each other.
20. The absorbent body according to claim 1, wherein the body
comprises at least two of said absorbent layers, which are arranged
in a substantially parallel disposition in relation to each other
and which overlap each other.
21. The absorbent body according to claim 18, wheren said absorbent
layers are arranged alternatingly so that, for a given layer, said
first strips have a longitudinal direction of extension being
substantially perpendicular to the direction of extension of said
first strips of the closest adjacent layer.
22. The absorbent body according to claim 1, wherein the material
of said first strips and of said second strips is chosen from a
group of fibrous materials, said group including cellulosic fibres,
synthetic fibres such as thermoplastic fibres of polypropylene and
polyethylene.
23. The absorbent body according to claim 1, wherein the material
of said first strips or of said second strips is chosen from a
group of fibrous materials, said group including cellulosic fibres,
synthetic fibres such as thermoplastic fibres of polypropylene and
polyethylene.
24. The absorbent body according to claim 1, wherein the material
of said first strips and of said second strips is chosen from a
group of non-fibrous materials, said group including foam-based
materials and materials in the form of a film.
25. The absorbent body according to claim 1, wherein the material
of said first strips or of said second strips is chosen from a
group of non-fibrous materials, said group including foam-based
materials and materials in the form of a film.
26. The absorbent body according to claims 1, wherein the material
of said first strips and of said second strips is chosen from a
group of absorbent materials, said group including cellulose pulp,
superabsorbents, absorbent foams, and absorbent synthetic
fibres.
27. The absorbent body according to claims 1, wherein the material
of said first strips or of said second strips is chosen from a
group of absorbent materials, said group including cellulose pulp,
superabsorbents, absorbent foams, and absorbent synthetic
fibres.
28. An absorbent product comprising a substantially
fluid-impervious layer and a substantially fluid-pervious layer,
wherein an absorbent body according to claim 1 is arranged between
the fluid-impervious layer and the fluid-pervious layer.
29. A method for manufacturing an absorbent body, comprising:
coupling a set of first strips and a set of second strips to each
other to form an absorbent layer of the body, providing said first
strips with cuts in which said second strips are arranged.
30. The method according to claim 24, wherein designing said cuts
so that flaps, which can be turned up or down in relation to said
first strips, are formed in said first strips.
31. The method according to claim 29, wherein the cuts are
substantially L-shaped cuts.
32. A device for manufacturing an absorbent body comprising a set
of first strips and a set of second strips, the device comprising a
first unit for feeding forward said first strips in the form of
strips, and for forming cuts in said first strips, to a device for
coupling together said first and second strips, and a second unit
for providing said second strips to the coupling device, the
coupling device comprises members for preparing said first strips
for the application of said second strips in the cuts of said first
strips.
33. The device according to claim 32, wherein said preparing
members are arranged for turning up or turning down flaps of the
first strips, said flaps being formed by said cuts.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims the benefit of U.S.
Provisional Application No. 60/530,669, filed in the United States
on Dec. 19, 2003, the entire contents of which are hereby expressly
incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to an absorbent body and a
method for manufacturing an absorbent body.
BACKGROUND OF THE INVENTION
[0003] Within a number of applications, there is a need of products
which are capable of absorbing a fluid. One such application is
hygiene products of different types, such as diapers, incontinence
guards, pantyliners, etc., which should be provided with an
absorbent body having the capacity of rapidly taking care of a
relatively large fluid quantity. Thereby, the absorbent body should
be capable of distributing the fluid and storing the fluid.
Usually, two or more layers, which can be made of different kinds
of material having different properties, are used in order to
create such an absorbent body. At the same time, it is desired that
the products are as thin as possible for a comfortable and discreet
use. Accordingly, a compressed absorbent body having a small volume
and a large absorption capacity is desirable. An absorbent body, or
core, which is compressed too much and/or the use of rigid
materials in the absorbent body, however, makes the product less
flexible and ductile and, consequently, less comfortable to
use.
[0004] Although the invention primarily is intended for providing
the above-mentioned products, its should be emphasized that the
invention also would be applicable to other similar products which
are to possess the capacity of absorbing a fluid.
[0005] One type of textiles having absorption capacity are those
manufactured by means of weaving. U.S. Pat. No. 4,695,500 describes
such a woven structure intended for medical products, such as
compresses, gauze bandages and the like. One property of woven or
braided structures is that they are proportionately flexible and
ductile even if they are made of a material which is rigid per
se.
[0006] U.S. Pat. No. 5,883,022 describes how an absorbent textile
is created by means of interweaving fibres, and especially how
synthetic, continuous fibres are used in order to attain a high
absorption capacity by means of alternatingly providing the textile
fabric with regions where the fibres are bound to each other and
with open regions where the fibres are non-bound to each other. The
interstitial spaces of the textile fabric which are formed in this
way enable fluid to be absorbed by means of the fluid being
distributed and retained in the interstitial spaces through
capillary action and adhesive forces.
[0007] In order to manufacture a woven textile, however, a
complicated manufacturing method is required in which the threads,
a warp and a weft, are interlaced. Due to its complexity, such a
method would not be a realistic alternative to the present
manufacturing methods for applications within the field of hygiene
products. Production of hygiene products by means of weaving would
not at all meet the demands upon production speed and cost
efficiency which prevail when producing these products.
Furthermore, when performing traditional weaving, it is required
that the material parts which are interwoven, usually threads, have
a sufficiently high strength, such as tensile strength, allowing
them to be handled in the way required by the weaving process
without being damaged. This means that many materials having a
proportionately low strength, but which with regard to certain
properties still could be suitable for use when forming an
absorbent body, cannot be used when manufacturing a woven
layer.
OBJECTS AND SUMMARY
[0008] It is an object of the invention to provide an absorbent
body being proportionately flexible even if it is made of a
proportionately rigid material.
[0009] A second object of the invention is to provide a method by
means of which method a proportionately flexible absorbent body can
be manufactured from a proportionately rigid material.
[0010] By means of using strips instead of a continuous layer, in
accordance with an embodiment of the invention, a more open and
flexible layer can be formed. As a result of said first and second
strips being coupled to each other in such a way that said first
strips are provided with cuts in which said second strips are
arranged, the strips can be locked in relation to each other, at
the same time as the layer can be designed so that the strips to a
certain degree can be displaced in relation to each other in
directions parallel to the formed layer. Furthermore, as a result
of said second strips being arranged in the cuts of said first
strips, the strips will locally be slightly curved, i.e. a
pre-initiated bending or deformation is present in one or several
positions, implying that the formed layer as a whole becomes more
flexible.
[0011] An additional advantage is that such a layer exhibits a
proportionately large exposed and to some extent irregular surface,
creating the necessary conditions for a good absorption of a fluid.
Furthermore, it is possible to design the absorbent body with
apertures and/or cavities in order to increase its fluid
acquisition capacity. Among other things, this implies that in case
of the occurrence of a so-called gel-blocking, something which may
occur for example in superabsorbent materials, such a fluid barrier
will at worst be present in the respective strip, but not in the
entire layer, something which could become the case if such a
material were to be used in a traditional continuous layer.
[0012] Furthermore, the production of the absorbent body can be
done in a rational and cost efficient way, also allowing the use of
materials which could not be handled when utilising other
manufacturing methods, such as weaving. The invention opens up for
the creation of absorbent layers made of a number of material types
and/or material combinations. For instance, the material in the
above-mentioned second strips can be varied within one specific
layer in order to give the layer different properties in different
regions. Also the relative position of the strips in the layer can
be varied, so that different properties are attained in different
layers or within one specific layer. For instance, the layer can be
given different density and/or absorption capacity in different
regions.
[0013] An embodiment of the invention also relates to an absorbent
product comprising a substantially fluid-impervious layer and a
substantially fluid-pervious layer, said product having an
absorbent body according to the invention arranged between the
fluid-impervious layer and the fluid-pervious layer.
[0014] Other features and advantages of the invention are evident
from the following description and the appended dependent
claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] A detailed description of exemplifying embodiments of the
invention, with reference the attached drawings, will follow
below.
[0016] In the drawings:
[0017] FIG. 1a is a schematic illustration of a first side of an
absorbent layer according to an embodiment of the invention;
[0018] FIG. 1b is an illustration of the opposite side of the layer
according to an embodiment of the invention in FIG. 1a;
[0019] FIG. 2 is a cut according to an embodiment of the invention
forming a variant of a flap of the layer;
[0020] FIG. 3a is a schematic illustration of a first side of a
variant of an absorbent layer according to an embodiment of the
invention;
[0021] FIG. 3b is an illustration of the opposite side of the layer
according to the embodiment in FIG. 3a, and
[0022] FIG. 4 is a schematic illustration of a device for
manufacturing an absorbent body according to an embodiment of the
invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS OF THE INVENTION
[0023] FIGS. 1a and 1b illustrate one embodiment of an absorbent
body according to the invention. FIG. 1a shows a first side of the
layer, and FIG. 1b shows the opposite side of the layer. The body
comprises a set of first strips 1 and a set of second strips 2,
wherein said first 1 and second 2 strips are coupled to each other
in order form an absorbent layer 3 of the body. The first 1 and
second 2 strips are coupled to each other by means of the first
strips 1 being provided with cuts 4, in which cuts 4 the second
strips 2 are arranged.
[0024] Although the illustrated embodiments of the invention
include a plurality of the first strips and a plurality of the
second strips, it is possible in other embodiments of the invention
to form the absorbent layer from an arbitrary number of first and
second strips. One, two or several of the first strips, which each
can be provided with one, two or several of said cuts, can be
coupled to one, two or several of the second strips. Accordingly,
it should be emphasized that the expression "a set of first/second
strips" means one, two or several such strips. Furthermore, the
number of first strips can of course be different from the number
of second strips. The layer preferably comprises two or several
first strips, and preferably two or several second strips. In the
most simple embodiment, however, the layer could be formed by a
first strip being provided with a cut, and a second strip being
arranged in the cut.
[0025] The cuts 4 can be said to have three main directions of
extension, a first extension constituting the length of the cut, a
second extension constituting the width of the cut and a third
extension constituting the depth of the cut. As far as the depth of
the cut is concerned, the cut suitably runs through the entire
thickness of the respective first strip 1. The width of the cuts 4
is suitably as small as possible. (The material which, if
necessary, still is removed when forming the cut is controlled by
the properties of the tool being used for achieving the cuts.)
Furthermore, the cuts 4 have an extension 5 in a longitudinal
direction which is substantially parallel to the longitudinal
direction 6 of said first strips 1 and an extension 7 in a
longitudinal direction which is substantially perpendicular in
relation to the longitudinal direction 6 of said first strips. In
this way, the respective cut 4 obtains a substantially L-shaped 8
extension. The length of a cut 4 in the direction substantially
perpendicular in relation to the longitudinal direction 6 of said
first strips can correspond to approximately half the width 9 of
one of said first strips 1. Furthermore, the length of said cut in
the direction substantially in parallel with the longitudinal
direction 6 of said first strips 1 can be of the same magnitude as
the width 9 of one of said first strips 1.
[0026] In the illustrated embodiments, the first 1 and second
strips 2 are arranged so that they cross each other. In another
embodiment, however, the second strips could be arranged in
parallel with the first strips. Thereby, the cuts of the first
strips would exhibit an extension which is substantially
perpendicular to the longitudinal direction of the first strips and
the second strips.
[0027] However, an embodiment having strips laid crosswise is
favourable for achieving a flexible structure. Suitably, the first
strips 1 are arranged substantially in parallel with each other,
and in a corresponding way the second strips 2 are arranged
substantially in parallel with each other. Furthermore, the first 1
and second strips 2 can be arranged substantially perpendicularly
in relation to each other.
[0028] Although the embodiment according to FIGS. 1a and 1b
exhibits substantially L-shaped 8 cuts 4, it should be emphasized
that the shape and dimensions of the cuts can be varied in a
multitude of different ways within the scope of the invention.
Examples of other possible designs is that the cuts have an
extension 10 corresponding to a portion of circle, such as a
semi-circle, or that the respective cut has an extension
substantially corresponding to a quarter of a circle, as
illustrated in FIG. 2.
[0029] In one advantageous embodiment of the invention, as
illustrated in FIGS. 1a and 1b (and 3a and 3b), the cuts are
arranged in order to form flaps 11 in said first strips. By means
of designing the cuts 4 so that flaps 11, or tabs, are formed in
the strips 1, a rational production of the absorbent body can be
attained. The flaps 11 may be turnable up or down in relation to
said respective first strip 1 for arranging one of said second
strips 2 between the respective flap 11 and said first strip 1.
When the flaps 11 are turned up, the second strips 2 can be placed
on top of the first strips 1, whereupon the flaps 11 are turned
down over the second strips 2. Along its extension in a
longitudinal direction 12, the respective second strip 2 preferably
is arranged between a plurality of flaps 11 and said first strips
1. Furthermore, FIG. 1a shows a schematic representation of how a
flap 11c can be turned up.
[0030] The first 1 and second 2 strips can be coupled together by
means of the cuts 4. By means of the cuts 4, the strips can be
locked from lateral displacement in one or both directions. The
length and position of the cuts 4 can be adapted to the width 13 of
the second strips, so that a certain lateral displacement of the
respective strip 2 can be allowed. In the embodiment according to
FIG. 1, the flaps 11 are arranged for locking said second strip 2
in relation to said first strips 1 in a first direction being
substantially parallel to the longitudinal direction 6 of said
first strips, and in a second, opposite direction. The flaps 11 are
arranged alternatingly on said first strips 1 so that, for a given
flap 11a, said second strip 2 is locked in relation to said first
strips 1 in a direction parallel to the longitudinal direction 6 of
said first strips 1 and, by means of the closest adjacent flap 11b
along said second strip 2, this is locked in the substantially
opposite direction.
[0031] In the example illustrated in FIGS. 1a and 1b, the
respective cut 4 is arranged for extending from a position 14 at
one of the longitudinal side edges 15 of said respective first
strip and further into the strip 1. Since a portion 16 of the
periphery of the respective flap 11 is formed by a portion 16 of
one of the longitudinal side edges 15 of the respective first strip
1, the total cut length which has to be achieved in order to create
the flap 11 can be reduced in comparison with a case when the
entire periphery of the flap 11 would be located inside the two
side edges 15, 17 of the strip.
[0032] It is also possible to arrange the first strips 1 and/or the
second strips 2 so that they partially overlap each other in a
lateral direction, as shown in FIGS. 3a and 3b. FIG. 3a shows a
first side of a variant of the layer 3, and FIG. 3b shows the
opposite side of the layer 3. In one advantageous embodiment of the
invention, the distance between the strips is varied, so that the
strips are arranged more densely in certain regions of the formed
absorbent layer 3. Due to the fact that the strips are arranged for
overlapping each other, for example a structure which is suitable
for a narrow crotch portion of a hygiene product exhibiting a
so-called "boostered" absorption can be obtained. In FIGS. 3a and
3b, it is illustrated how the first strips 1 overlap each other in
a lateral direction in order to form a more dense structure, but it
is of course also possible to arrange the second strips 2 so that
these overlap each other.
[0033] Of course, even if not illustrated, also the second strips
could exhibit cuts for receiving said first strips in order to
achieve an additional locking and coupling together of the
strips.
[0034] In order to build up a thicker absorbent body and/or in
order to attain other properties than those exhibited by a layer,
the absorbent body can include two or several of said absorbent
layers on top of each other. The layers, being arranged for
overlapping each other, can be arranged in a substantially parallel
disposition in relation to each other. In one embodiment, the
absorbent layers are arranged alternatingly so that, for a given
layer, the first strips have a longitudinal direction of extension
which is substantially perpendicular to the direction of extension
of the first strips in one of the closest adjacent layers. The
first and second strips could be arranged in order to "change
places" from one layer to the closest adjacent layer, i.e. when
moving in the z-direction or, in other words, from one layer to
another in the thickness direction of the layers, the next layer is
turned approximately 90.degree. in relation to the preceding
layer.
[0035] The first strips 1 and the second strips 2 can exhibit a
width 9, 13 within the interval from a few millimetres to about a
hundred millimetres, preferably within the interval 5-100 mm, and
usually within the interval 15-35 mm. The thickness of a strip can
vary between one or a few tenths of a millimetre to tens of
millimetres, preferably within the interval 0.1-10 mm. A strip of
nonwoven material, for instance, can have a thickness which is
about 0,5 mm, and a strip of cellulose pulp can have a thickness
which is about 10 mm. The thickness and width of the strips 1, 2
are decided by the properties desired from the layer 3, and in
dependence of which material the strips are made of. Both absorbent
and non-absorbent materials are included amongst the materials
which could be used. Examples of different materials are cellulose
pulp, woven fabrics, nonwoven fabrics, fibrous materials,
non-fibrous materials, foam materials, superabsorbent materials,
synthetic materials such as thermoplastic fibres, and others.
[0036] The invention makes it possible for materials which are more
rigid per se to form flexible products and, accordingly, more rigid
materials are more preferred than soft materials, since soft or
flexible materials can be used also in conventional structures.
Examples of such more rigid materials are compressed materials, for
example compressed cellulose pulp, such as, CP, TMP, CTMP, etc.,
compressed foam, compressed nonwoven or tissue laminates containing
superabsorbents. Additional examples of rigid materials are
materials in the form of a film, and especially different
superabsorbents in the form of a film.
[0037] In one embodiment of the invention, the layer illustrated in
FIG. 1a is formed by first strips made of cellulose pulp, either
chemical pulp, CP, or such pulp blended with synthetic fibres so
that the strips have a fibre content within the interval 2-15% by
weight, preferably 10% by weight. The width of the strips is about
15 mm and the thickness is about 1-3 mm. The seconds strips are
built up as laminates having an upper and a lower tissue layer,
each with a thickness about 0.2 mm, and a layer of a superabsorbent
arranged between the tissue layers, said superabsorbent layer
having a thickness of about 1-3 mm. The width of the second strips
is about 15 mm.
[0038] With regard to the dimensions and materials which can be
used in order to create an absorbent body according to the
invention, three examples of the first and second strips will
follow below.
EXAMPLE 1
[0039] An above-mentioned first strip consists of 285 g/m.sup.2 CP,
50 g/m.sup.2 superabsorbent of a conventional type and 15 g/m.sup.2
polypropylene. The components are blended and compressed, and are
formed into a strip having 2 mm thickness and 15 mm width.
[0040] An above-mentioned second strip is a laminate and consists
of 400 g/m.sup.2 superabsorbent of a conventional type which is
arranged between two tissue layers, 20 g/m.sup.2 each. The strip is
manufactured having a total thickness which is 1 mm and a width
which is 15 mm.
EXAMPLE 2
[0041] An above-mentioned first strip consists of 125 g/m.sup.2 CP
and 50 g/m.sup.2 superabsorbent of a conventional type. The
components are blended and compressed, and are formed into a strip
having 0.5 mm thickness and 15 mm width.
[0042] An above-mentioned second strip is a laminate and consists
of 400 g/m.sup.2 superabsorbent of a conventional type which is
arranged between two tissue layers, 20 g/m.sup.2 each. The strip is
manufactured having a total thickness which is 1 mm and width which
is 15 mm.
EXAMPLE 3
[0043] An above-mentioned first strip consists of 125 g/m.sup.2 CP
and 50 g/m.sup.2 superabsorbent of a conventional type. The
components are blended and compressed, and are formed into a strip
having 1 mm thickness and 15 mm width.
[0044] An above-mentioned second strip consists of 175 g/m.sup.2
CP, 70 g/m.sup.2 superabsorbent of a conventional type. The
components are blended and compressed, and are formed into a strip
having 3 mm thickness and 15 mm width.
[0045] An embodiment according to the invention for manufacturing
an absorbent body comprises the steps of coupling a set of first
strips 1 and a set of second strips 2 to each other in order to
form an absorbent layer 3 of the body and, furthermore, that the
first 1 and second 2 strips are coupled to each other by means of
providing the first strips with cuts 4, in which cuts 4 the second
strips 2 are arranged. In one advantageous embodiment, the cuts 4
are designed so that flaps 11 which can be turned up and down in
relation to the first strips 1 are formed in the first strips 1.
The flaps 11 of the first strips 1 are turned aside and the second
strips 2 are arranged on top of the first strips 1, whereupon the
flaps 11 are turned back over the second strips 2. To this end, the
first strips 1 can be provided with, for example, substantially
L-shaped 8 cuts 4 or cuts having another suitable shape as
described above.
[0046] FIG. 4 is a schematic illustration of an embodiment of how
the method according to the invention can be realized and,
furthermore, of a device for manufacturing a layer 3 from a set of
first strips 1 and a set of second strips 2. The device comprises a
first unit 20 for feeding forward said first strips 1 in the form
of continuous strips, and for forming cuts 4 in said first strips
1, to a means 21 for coupling together said first 1 and second
strips 2, and a second unit 22 for providing said second strips 2
to the coupling means 21. Furthermore, the coupling means 21
comprises members 23 for preparing said first strips 1 for the
application of said second strips 2 in the cuts 4 of said first
strips 1.
[0047] The second unit 22 can be a storage 24 from which said
second strips 2 can be provided. Of course, one or several
storages, or another device having the corresponding function, can
be used for providing said second strips, preferably piece by
piece, to the coupling means 21. Instead, it is also possible to
feed the second strips from one or several rolls, and to cut these
strips into desired lengths in connection with the application of
these on the first strips. In the illustrated example, the second
strips 2 are placed so that said first 1 and second 2 strips cross
each other, and preferably so that the first 1 and second 2 strips
are arranged substantially perpendicularly in relation to each
other. The first strips 1, which preferably are continuous strips,
are fed forwards to the coupling means 21. Although different
techniques for cutting, punching or shearing can be included for
achieving the cuts 4 according to the invention, FIG. 4 shows a
schematic illustration of an embodiment where a cutting roll 25, or
so-called RDC-technique (Rotary Die Cutting), is used in order to
provide the first strips 1 with the requisite cuts 4. Suitably, a
plurality of said first strips 1, being arranged next to each other
along a direction substantially perpendicular to the direction of
feed 26, are fed forwards simultaneously, for example by means of
one or several pairs of rolls 25, and thereby the strips are
provided with requisite cuts 4 by means of said RDC-technique.
[0048] The length of the second strips 2 is adapted to the desired
width of the formed layer 3. In the embodiment in which said second
strips 2 are placed substantially perpendicularly in relation to
the direction of feed 26 or, in other words, substantially in
parallel with the longitudinal direction of the rolls, the length
of said second strips 2 can be substantially equal to the distance
between the two outermost first strips 1.
[0049] The coupling means 21 can include a roll 27 being provided
with said members 23, such as spikes 28 protruding from the roll 27
or drum, for preparing the first strips 1, for example by means of
turning up said flaps 11 being arranged on the first strips 1, so
that the second strips 2 can be arranged in the cuts 4.
Furthermore, a turning-down means, such as an additional roll 29,
or a brush or the like, which is not necessarily rotatable but only
abuts against the roll 27, can be arranged for turning the
up-turned flaps 11 back down when the second strips 2 have been
arranged in their intended positions. In such a case, the spikes 28
of the first roll 27 suitably exhibit the property that they can be
folded aside or retracted into the roll 27 when said additional
roll 29 turns the flaps 11 of the first strips 1 back down.
[0050] Before the first strips 1 are provided with cuts 4, if
desired, the strips can be coated with an additional layer 30 of
another material, such as a nonwoven, for example with the object
of improving the tensile strength of the first strips 1 and,
consequently, of the absorbent layer 3 and the absorbent body
formed by the strips. The material for the additional layer can be
delivered, for example, from a roll 31.
[0051] It is emphasized that the invention is not restricted to the
embodiments of the invention described by way of example, but a
plurality of variants and modifications of the invention within the
scope of the subsequent claims and equivalents thereof will become
evident to the skilled person once the inventive idea has been
disclosed. For instance, the first strips could exhibit cuts having
only one longitudinal direction of extension which is substantially
parallel to the longitudinal direction of the first strips. The
cuts could be of approximately the same length, or somewhat longer
than the width of the second strips. Thereby, no real flap which
can turned aside is created, but the coupling together of the
strips and the forming of the absorbent layer would in this case
take place by means of the second strips being inserted into these
cuts.
[0052] Although only preferred embodiments are specifically
illustrated and described herein, it will be appreciated that many
modifications and variations of the present invention are possible
in light of the above teachings and within the purview of the
appended claims without departing from the spirit and intended
scope of the invention.
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